Automatic machine



June 6, 1944. A. M. LOUNGWAY 2,350,515

AUTOMATIC MACHINE Filed June 24, 1942 12 Sheets-Sheet 1 June 6, 1944- A. M. LOUNGWAY AUTOMATIC MACHINE Filed June 24, 1942 12 Sheets-Sheet 2 1NV NTOR.

' ATTORNEY.

IWNM wwm Julie 6, 1944. LOUNGWAY 2,350,515

AUTOMATIC MACHINE Filed June 24, 1942 12 Sheets-Sheet 5' Flt-3.3.

g %I ENTOR.

ATTORNEY.

June 1944- A. M. LOUNGWAY 2,350,515

AUTOMATIC MACHINE Filed June 24, 1942 12 Sheets-Sheet 4 I m I 5k- FIG.%.4I WV 7 0 V {ad I I I 28 ill Has. 2'

---monm L mum V June 6, 1944.

A. M. LOUNC-WAY AUTOMATIC MACHINE Filed June 24, 1942 12 Sheets-Sheet 5 Z flglVY/ENTOR.

A T TORNE' Y.

12' Sheets-Sheet 6 INVENTOR KW A TTORNEY My M "lull! lillkl AUTOMATIC MACHINE A. M. LOUNGWAY Filed June 24, 1942 June a, 1944.,

June 6, 1944. A. M. LOUNGWAY AUTOMATIC MACHINE Filed June 24, 1942 12 Sheets-Sheet 7 WWW 11v VENTOR. y ATTORNEY WWW 5E Q m.

June 6, 1944. A, M, LUNGWAY 2 2,350,515

AUTOMAT IC MACHINE Filed June 24; 1942 12 sheets-sheets IN V TOR.

A TTORNE Y.

June 6, 1944. A. M. LOUNGWAY AUTOMATIC MACHINE l2 Sheets-Sheet 9 Filed 'June 24, 1942 ATTORNEY.

I VENTOR. /,4-7& BY

June 6 1944.

A. M. LOUNGWAY 2,350,515 5 AUTOMATIC MACHINE Filed June 24, 1942 12 Sheets-Sheet 10 lillll} F'IG.20.

1 ATTORNEY June 6, 1944. A. M. LOUNGWAY AUTOMATIC MACHINE 12 Sheets-Sheet 11 Filed June 24, 1942 ATTORNEY.

yzLN VEN TOR.

12 Sheets-Sheet 12 A. M. LOUNGWAY AUTOMATIC MACHINE Filed June 24, 1942 \N uh June 6, 1944.

a fi %yVENTOR.

ATTORNEY.

Patented June 6, 1944 to International Business Machines Corporation, New York, N. Y., a corporation of New York Application June 24, 1942, Serial No. 448,328-

11 Claims.

This invention relates to a machine for the automatic manufacture of brushes, for example contact brushesof the type used in electrically operated tabulating machines and other machines of similar character. These brushes are composed of one or more tufts of wire bound together at one end. Heretofore, as far as I am aware, the most expedient method of making such-brushes has been by die casting a slug of metal upon the wires, to bind them into a unit.

A machine embodying my invention makes brushes having the tuft or tufts of wires set in a ferrule crimped upon them. The machine comprises a turret having an intermittently rotated index member, to which the ferrules are supplied at one station, while at another station a complement of wires is threaded into each ferrule. In a preferred form of the machine the ferrules, with their complements of wires, are ejected from the index member into a finishing mechanism, which crimps the ferrules upon the wires and shapes them to the desired finished form and size.

The machine preferably includes means for re moving burrs and dirt from the ferrules before the wires are threaded into them and means for spreading them'slightly at the end which is to receive the wires.

It is also preferably provided with means to indicate any failure of the various parts of the machine to perform correctly, any irregularities of the wires, or any accumulation of dirt on the index member, where it might interfere with the operation of the machine.

The principal object of the invention is to provide a machine of the character described which will produce brushes at a rapid rate and at lower cost than heretofore possible.

Another object is to provide a machine which will manufacture brushes of uniformly good quality, with a minimum of attention, beyond the maintenance of the supply of'material's going into the manufacture.

Another object is to provide a machine which will indicate the source of any disturbance in its operation or defect of the wires, so that the operator can quickly correct the condition.

Another object is to provide abrush making machine which will feed exact lengths of small gage tube and wire into the machine, without injury to such materials.

Another object is to provide a brush making machine which will thread a bunch of wires into a, ferrule of only slightly larger bore than the cross section of the bunch.

Another object is to provide a brush making machine which will thread into a ferrule a bunch of wires comprising several tufts of wires separated by spacers, the wires being fed through the ferrule far enough to project. beyond it to a predetermined length, while the spacers are fed a shorter distance, so as to be substantially contained within the ferrule.

Other objects of the invention will be pointed out in the following description and claims and illustrated inthe accompanying drawings, which disclose, by way of example, the principle of the invention and the best mode, which has been contemplated, of applying that principle.

In the drawings: I Fig. 1 is a side elevation of the machine, slightly broken away at its extremities.

Fig. 2 is a plan view of the principal parts of the machine, minus the wire supply reels and tube reservoir.

Fig. 3 is a plan view of a portion of the machine including the tube feeding mechanism and a part of the main drive mechanism.

Fig. 4 is a transverse vertical section on the line 6& of Fi 3.

Fig. 5 is a vertical section on the line 55 of Fig. 4.

- Fig. 6 is a plan view of the turret and appurtenant mechanisms at the various stations surrounding it.

Fig. 7 is a vertical section on the line of Fig. 6. V l

8 is a plan view of the turret with the cover plate removed.

Fig. 9 is a vertical section through the turret on the line. 9--9 of Fig. 6.

Fig. 10 is a detail vertical section on the'line I0-I0 of Fig. 6 showing the restoring means for the brush ejectors.

Fig. 11 is a detail vertical sectional view on th line Il-il of Fig. 6, showing the index member locking mechanism.

Fig. 12-is a vertical section on line 02-42 of Fig. 2 showing the tube cut-off mechanism.

Fig. 13 is a vertical section on the line l3--l3 of Fig. 2.

' Fig. 14 is a detail vertical section on the line ill-l6 of Fig. 6,-showing the ferrule spreading mechanism.

Fig. 15 is a detail vertical section on the line l5-l5 of Fig. 6, showing a detector switch for detecting the absence of a ferrule in a receptacle of the index member.

Fig. 16 is a vertical transverse section through the reciprocating wire feed mechanism.

Fig. 17 is a vertical longitudinal section through the same mechanism.

Fig. 18 is a detail vertical section of the brush wire clamping means of the same mechanism.

Fig. 18a is a side elevation of one of the wire clamps shown in Fig. 18.

Fig. 19 is a similar vertical section of the spacer wire clamping means.

Fig. 20 is a similar vertical section of the wire clamping means at the needle of the wire threading unit.

Fig. 21 is a sectional plan view of the reciprocating wire feeding mechanism.

Fig. 22 is a detail view of an electrical contact for detecting irregularities in the wire.

Fig. 23 is a horizontal sectional view of a portion of the wire supply creel, on the line 23-23 of Fig. 1, showing an electrical' contact device for detecting kinks in the wire.

Fig. 24 is a vertical sectional view of the rotary wire feeding device.

Fig. 25 is a side elevational view of the ferrule sizing and straightening unit, showing a portion of the turret adjacent thereto in section.

Fig. 26 is a transverse sectional view through the sizing and straightening unit, at the sizing rolls.

Fig. 27 is a longitudinal sectional view through the sizing and straightening unit on the line 21-21 of Fig. 26, showing the driving gears.

Fig. 28 is a horizontal sectional view of a portion of the sizing and straightening unit along its median plane.

Fig. 29 is a side elevational view of the brush produced by the machine.

Fig. 30 is a transverse section on a larger scale, through the ferrule of the brush.

Fig. 31 is a wiring diagram of the machine.

The machine shown in the drawings by way of example is designed for the manufacture of electrical contact brushes of the type shown in Figs. 29 and 30. These brushes comprise three tufts of brush wires B separated by spacer wires S and bound in a ferrule 3. The brushes leave the machine in the form shown in these figures and are ready for use after grinding off the tip of the tufts B to a certain angle. There are three tuftsof brush wires B, each composed of six round wires, and two spacer wires S of rectangular cross section separating the tuft of brush wires. The ferrule is made from-a leng h of tube of rectangular cross section having a bore only slightly larger than the bundle of wires and spacers. The ferrule is rolled to the I beam shape shown, in the finishing mechanism, and thereby crimped against the bundle .of wires and spacers, tightly setting them in place.

The general arrangement of the machine can be seen from Figs. 1 and 2. The rectangular tubes from which the ferrules are cut are held in a rack 5 and fed toward the right by a. reciprocating feeding unit 6, through a clamp and cut-off station I, to a turret 8 comprising a rotary index ring 9. The ferrules cut off from the tubing are individually received in receptacles l6 formed by supplied from reels i3 mounted on a creel frame composed of horizontal and vertical pipes l4. The wires leaving the reels pass through guides l5 to a guide and electrical contact device I6 to be referred to later. They then run over pulleys l1 and I! to a rotary feeding drum l9 and from there converge into a reciprocating wire feed unit 20. The spacer wires S are supplied from reels not shown inv-the drawings to the same reciprocating wire feed unit 26, passing above the brush wires B at the feeding drum l9. When the wires have been threaded through the ferrule and extend beyond it to the correct length. as shown in Fig. 29, the feed of the wire stops and the wires are cut off at the outer end of the ferrule by a cutting wheel 23. The index ring then turns further and the assembly of wires and ferrule reach the ejection-station 24, where they are elected and passed through a sizing and straightening unit 25. The finished brushes are dropped through a chute 26 into a packing box 21 on a support 26.

Some of the mechanisms of the machine are operated by a cam shaft 30 driven by a large motor, which does not appear in the structural views, and the other mechanisms by four fractional horsepower motors. Three of these smaller motors appear in Fig. 2. namely, a motor 2| driving the wire cut-off wheel 23, a motor 32 operating the wire feeding drum i9, and a motor 33 driving the brush sizing and straightening unit 25. The fourth fractional horsepower motor 34,

shown in Fig. 12, drives the saw 35 of the tube cut oflf station I.

Another principal unit of the machine shown in Figs. 1 and 2 is the control box 40. This control box has four maintained-contact switches for the respective fractional horsepower motors, op-

erated by starting buttons 4| and stop buttons 42. A fifth maintained contact switch for the main driving clutch is operated by a starting button 43 and stop button 44. There is associated with each of the switches for the fractional horsepower motors a signal light 45, which is on whenever the corresponding motor is in operation. A signal light 46 is on whenever the main clutch is engaged. A jog button 41 operates a switch to engage the main clutch as long as the button is held down by the operator. A series of four signal lights 48, 49, 50 and Si serve to indicate the location of trouble when the machine is automatically stopped, in a manner to be described.

The cam shaft 30 is driven through a reduction gearing GI, 62, 63 (Fig. 3) housed in a casing 66; Power enters the reduction gearing through a shaft upon which is pinned a pulley 66. A belt 61 is trained over this pulley and a driving pulley 68 pinned to the shaft 69 of a clutch housed in a casing Ill. The structure of the clutch, which may be of standard design. is not shown. It is electromagnetically operated in a manner to be described with reference to the wiring diagram later on, and serves to clutch the main driving motor to the driving mechanism just described.

The turret The construction of the turret is shown particularly in Figs. 2, 6, '7, 8 and 9. A A circular block 16 is secured upon the upper face of a bed 16, leaving a bearing shoulder ll upon which freely rests the index ring 9. A cover 18 removably secured to the block 15 by screws not shown fits over the index ringwith small clearance, making the fourth side of the ferrule receptacles I0. A portion of the shoulder 11 is cut away beneath the index ring, as shown in Fig. 7 and in the space thus provided operates the index ring feed dog 62. This dog is rock'ably supported by a pin 83 upon a pair of rockers 84, pivotedby a pin 66 to of the dog 82 hasan upwardly turned finger 88 bearing upon a cam 89 on the cam shaft 30, which throws the hook 90 of the dog into one after another of a series of notches 9I on the lower face of the index ring 9. In each' of the notches the hook 90 bears upon a hardened pin 92 forced into a vertical bore 93 in the index ring at the forward side of the notch. A pair of links 95 are pivotally connected to the pin 83 at their right ends and are provided at their left ends with cam follower pins 96 bearing upon two identical cams 91 on the cam shaft 30. The links 95 are guided on the cam shaft by bearing surfaces 98 and are biased toward the right by a spring not shown in the drawings. The dog mechanism rotates the index ring at each stroke the distance between two pins 92, which is exactly the distance be-' tween two ferrule receptacles I0, as can be seen from Fig. 8.

Tube jeed.-The tubes T are fed from the rack 5 to the clamp and cut-01f station 1by a reciprocating mechanismfi (Figs, 1, 2, 3, 4, 5), comprising a car I provided with Wheels IOI traveling upon rails I02 fixed in the cavity of .a bolster block I03. The wheels are confined by plates I04 secured to the top of the bolster block by screws 99. The top of the car I00 is formed with two shoulders I between which is a slot of the same width as the longer cross sectional dimension of the tubing T. An elongated clamp bar I06 is freely held in the slot and rests upon the tubing T over its entire length. The clamp bar is operated from the cam shaft 30. In a bearing I01a of a supporting arm I01 is journaled a short shaft IBM, to one end of which is pinned the hub of an arm I08. The end of arm I08 carries a roller bearing I09, the outer race of which rests'upon the clamp bar I06. A second arm IIO pinned by its hub to rock shaft I08a extends over cam shaft 30 and is formed at its end into a socket III holding a cam follower, comprising a shaft II2 on which is journaled a roller H3. The shaft H2 is pressed downward by a spring II4 so that its roller bears yieldingly upon a cam II5 of shaft 30.

The car I=00 is reciprocated by cam shaft 30. A round bar H6 is slidably guided at its left end in a bearing I I1 on the frame 81, and its right end extends into a hollowappendage II8 of the car I00. The bar II6 has fixed upon its right end a collar II9 held normally ata middle position in the cavity of the appendage by two springs I20 and I2I. A lever I25 mounted by a pivot I26 on frame 81 is forked at one end to embrace a headed pin I21 fixed to the bar H6. The other end of the lever I25 has an upwardly directed boss I28 extending into a cam groove I29 of a barrel cam I30 of cam shaft 30. Rocking of the lever I25'by cam groove I29 moves car I00 to the right in Fig. 5, until a stop screw I3I strikes a dowel-pin I32; any further movement: of the lever I25 being taken up 'by the spring I20. Prior to the beginning of the rightward movement of the car I00, the high part of cam II5 moves under roller 3 and the clamp I06 is pressed upon the tube T with a yielding pressure distributed over a. considerable length of the tube, thus providing sufficient frictional contact to feed the tube while avoiding injury to its thin walls. The' 'e ffective stroke of the clamp car, whichdetermines the length of the ferrules cut oif'from thtub, is adjusted by means of the screw I3I. Before the return movement of the car the roller H3 rides off the high part of cam II5, releasin the turret, so that the operator is warned to start a new tube into the machine. Outside of the shoulders I05 are two bearings I35 to which a bail I36 is pivotally attached. The left end of the bail, as seen in Fig. 5, has fixed to it a finger I31 composed of insulating material which rests upon the tube T. When the finger I31 is supported by a tube it holds the bail I36 slightly above the shoulders I38 of the car I00. When the tubing is exhausted and the finger I3 1 drops, the bail comes in contact with the shoulders I38. The bail is insulated from the bearing I35 and is connected by a wire (not shown) to a circuit to be described later. Thiscircuit is closed when the bail I36 grounds against the shoulders I38. The tube is guided to the cam through a,

guide I39 mounted on the appendage II8.

Tube clamp and cut-017 station.The tube feeding mechanism delivers the tube to the tube clamp and cut-off station 1 (Fig. 2), which combolster I03 by knurled headed screws I46 and to the cover plate 18 of the turret by screws I 41,

The first section' I43 of the guide comprises a bottom plate I48 and two stationary shoulders I48, I49. Below the shoulder l49 is a horizontal slot in which slides a transversely movable clamp jaw I 50, the left edge of which is opposed to a solid vertical face of the shoulder I48. The tube is fed between the jaw I50 and the vertical face of shoulder I48. The jaw I50 has an enlarged portion I5I in which are fixed two dowel pins I52 having a sliding fit in two holes I53 of the shoulder I49 and serving to guide the jaw I50. The jaw is articulated by a joint I55, 2. plunger I56, a socket I51, and a spring I58 in the socket bearing against plunger I56, to an actuating arm I59 pivoted at I60 to a bracket I8I on the frame 81.

The arm I59 hasa nose I62 which bears against two plates I69 and I10 joined in spaced relationby a web IN. The plate I69 has two bevel flanges I12 and I13 fitting .in a guideway formed by two beveled bars I14 and I15 fixed by screws I16 to thebed 16. A shaft I journaled in the lower end of the plates I69 and I10 has pinned to it a sprocket wheel I8I. A chain I82 is trained over this sprocket wheel and a sprocket wheel I83 fixed to the saw arbor I61. .The shaft I80 also has pinned to it a pulley I19 driven by a belt I84 leading to a pulley I85 on, the shaft of motor 34. The lower endof the frame I68 is articulated by a link I86 to one end of a lever I81 pivotally supported by a pin I88 upon a bracket I89secured to the frame 81. A The opposite end of lever I81 is connected by a" pin I90 to a pitman I9I guided in a bearing I92-fixed to the frame 81.

, ring 9 are in the same plane. projects downward into;this space and is biased The upper end of pitman I 9I has fixed to it a pin I93 which bears against a cam I94 of shaft 90 by the weight of the saw unit supported by the opposite end of lever I81. It will be observed that as the cams I63 and I94 rotate in the direction of the arrow in Fig. 12, the clamp jaw I50 is first yieldingly pressed against the tube by the operating arm I59, then-cam I94 gradually depresses the pitman I9I, thereby raising the saw through the tube. The stroke of the saw is complete when the cam I94 has turned 180 from the position shown in Fig. 12. Just beyond this point anoutside cam I95 is positioned in fixed relation to the cam I94, to engage the pin I93 of the pitman and retract it. The clamp jaw I50 is engaged at the end of the feed stroke of the car I and continues through the return stroke of the car, which takes place during the cut-off stroke of the saw. a The length of tube cut off by the saw is at first supported by the section I65 of the tube guide, in a preparatory position for feeding to the index ring 9. The length of the tube cut off is exactly equal to the distance between the right side of the saw and the left side'of the index ring 9 and the length of the effective stroke of the tube feeding mechanism previously described is equal to the length of tube cut off, plus the width of the saw kerf. At the time the tube feed occurs the index ring stands with an empty receptacle I0 exactly aligned with the feeding path of the tube. Thus the feed of the tube presses the previously cut off length of the tube supported in the guide section I65, into the ready receptacle of the index ring, until its trailing end comes just flush with the outer surface of the index ring 9. Means are provided to stop the machine and give a signal if the tube is not fed exactly the required distance. There is shown in Figs. 6 and 13 a switch box 200 from which projects a switch operating button 20I, to be actuated by a feeler lever 202 pivoted at 203 to a bracket 204 on the switch box. The lower end of the lever is biased by button 20I against the inner edge of the ring 9, as the ring turns from one index position to the next, and moves to the left into the empty tube receptacle I0 arriving at the tube receiving position. If the feed of the tube is just enough to move the feeler lever 202 out of the slot I0 so that the end of the new tube length comes fiush with the inner surface of the index ring 9, the switch in box 200 is positioned to permit continued operation of the machine, as will be described later with reference to the wiring diagram. If the tube rocks the lever 202 too far, or not far enough, the machine will stop.

Two steps of the index ring from the tube feeding station just described, the newly inserted ferrule encounters a feeler contact 205 (Figs. 6 and 15), the object of which is to detect any receptacle which may have failed to receive a ferrule. The feeler contact 205 comprises a cylindrical box 206 having a flange 201 secured to the turret cover 18 by screws 208. The box 206 fits into a cyl ndrical hole 209 in the turret cover 18, leaving a space between the bottom of the box 206 and the top surface of .the index ring 9. The top surfaces of the ferrule F, and the index A feeler point 2I0 against the top surface of the index ring and the ferrule surfaces in the same plane therewith, by a spring within the box 208. If any receptacle of-. the index ring should be empty, the feeler point 2I0 would drop into it and thereby close a switch in the box 206, establishing electrical contact betweenthe ground and a terminal 2I I- connected by a wire :12 in a circuit controlling the main clutch, which will be described later.

Broaching station-After travel from the tube feeding station, the ferrule arrives at the broaching station, the position of which is indicated by the ferrule stop 2I5 in Fig. 6. The ferrule stop is fixed to the cover 10 by screws 2I6 (Fig. 9) and has at its lower edge a small aperture. 2 which is located opposite the opening of the ferrule when the latter is in the broaching station. The aperture 2 is slightly smaller than the outer dimensions of the ferrule.

The broaching mechanism comprises a reciprocating slide 220 (see also Fig. 8) having flanges 22I which rest upon shoulders 222 formed at the sides of a cavity 223 inthe block 15. The flanges 22I are covered by plates 224 secured to the block 15 by screws 225. At the top of the slide 220 is a slot 226 in which is firmly held a broach 221. A pin 228 stops the broach at its rear end. The block 15 has a guide lug 229 with a slotted guideway 230 for the broach 221. The cover 18 retains the broach in place.

The broach slide 220 is connected with its operating mechanism by a downwardly facing rack bar 235 thereon meshing with a pinion 236 which projects up through a slot 231 in the block 15. The pinion 236 is journaled upon a shaft 238 in a cavity 239 of the bolster block 16. At its lower side the pinion meshes with a rack bar 240 fixed to a pitman 24I guided in a slot 242 of the bolster block 16. At its right end the pitman 24I carries a roller 243 which travels between the floor of the slot 242 and a guide plate 244. The pitman 24I has an upwardlyextending arm 245 carrying a roller 246 which travels in th groove 241 of a face cam 248 of cam shaft 30. When the slide 24I is moved to the left, th broach 221 is thrust to the right into the ferrule held by the stop 2 I 5. In Fig. 9' the mechanism is at the middle of its operative stroke. The broach removes any burrs on the ferrule bore and cleans out any dirt therein.

Expanding tool.--On index step beyond the broaching station the ferrule arrives at an expanding or bell mouthing station (Figs. 6, 8 and 14). A tool holder 250 has fixed in it two guide pins 25I slidably received in two parallel holes, one of which is indicated at 252 in Fig. 14. Between the guide pins 25I a spring 263 is socketed in a hole 254 of the tool holder and a hole 255 in the cover 18. The spring pushes the tool holder outward against an operating arm 256, which is pivoted to the bed of the turret at its lower end, by means which do not appear in thedrawings. The arm 256 bearsupon a earn 251 of the cam shaft 30. The tool 258 firmly fixed in the tool holder 250 is adapted to penetrate into th outer end of the bore of the ferrule F and is slightly tapered so as to spread the bore a little, in order to facilitate the threading of the wires into the ferrule later on. During the bell mouthing operation, the ferrule is supported at its inner end by a detent 259, which is pivoted at 260 to the block 15 and yieldingly urged by a spring (not shown) against the inner end of the ferrule. The detent 259 swings back out of the ferrule as the index ring steps forward.

Index ring loch-Means may beprovided to center and lock the index ring at each index position. Referring to Figs. 6 and 11, there is shown a centering pin 265 slidably mounted in a vertical bushing 266 in a hole 261 in the bed 16. The pin 265 is biased upward by a spring 288, the lower end of which rests upon a screw 289 screwed into the bed 16. The index ring 3 has centering sockets defined by tapered bushings 210 spaced at intervals corresponding to one step of movement of the index ring. Fig. 11 shows the index ring midway in its movement from one index position to the next. The bushing 228 and the pin 255 are apertured at 2 and 212 to admit the end of an actuating lever 213 pivoted upon a pin 214 in a cavity 215 of the bed 16. The right end of the lever 213 carries a roller 216 bearing upon a cam 211 of the cam shaft 30. The cam 211 rocks the lever 2-13 clockwise when each feed movement of theindex ring has been completed to center and lock the ring in its index position.

Wire threading station After 180 of travel from the tube feeding station, the ferrule arrives at the wire threading station, where in accordance with the constructhem wire guides l through which the wires pass to a guide and contact unit l6, where any kinks or irregularities of the wire are detected. As shown particularly in Fig. 23, this unit comprises a block 52 secured to the frame pipe 14 by a U- bolt 58. Upon the rear face of the block 52 is a sheet of insulation 58 to which two contact plates 54 are secured. There are registered holes 54a, 56a and 52a in the contact plate, insulation. and block. Upon the front face of the block are welded elongated sockets 53 containing apertured guide blocks 51, the holes of which are aligned with the holes 52a. The wires are guided by the guides l5 (Fig. l) and 51, so that they normally pass through the holes 54a without making contact with the plate 54. The plate is connected in a circuit to be described later, whereby the machine is stopped and a signal given showing the cause of the interruption, if any kink or bend in one of the wires brings it into contact with the side of its hole 54a.

The brush wires B pass from the contact unit 15 over pulleys I1 and I8 to the wire feeding drum I9 (see also Figs. 2 and 24). This drum is journaled by its shaft 280 in a bearing bracket 28f mounted on the frame 81. The shaft 280 has fixed to it a gear 282 meshing with a gear 283 on the worm wheel shaft 284 of a reducing gear housed in a casing 285. The reducing gear is driven by motor 32. The eighteen wires from pulley l8 pass through holes in a guide 286 mounted on arm 281 of the'bearing bracket 28l and, after taking a turn around the drum I 9, pass out through holes in a guide 288 on an arm 288 of the bearing bracket 28!. The drumv I9 is rotated continuously by motor 32 in the direction of the arrow but the brush wires B are only fed by the drum when snubbed by a leftward movement of the reciprocating wire feeding mechanism ,20 (Fig. 2) to which the wires pass from the drum l9. The spacer wires S, which come from two reels not shown in the drawings, run through a guide 290 supported on arms 281 and 288, without taking a turn around the feed drum l9.

The detail construction of the reciprocating wire feeding mechanism 20 can be seen 16 to 22. A car 300 is carried by wheels 30! upon tracks 302 in a trough 303 of a bolster block 304 mounted on the frame 81. The wheels are retained by plates 299. The car has fixed to its bottom a rack bar 305 meshing with a gear 308 fixed to a shaft 301 iournaled in a downward extension 308 of the car. A gear 309 fixed to the opposite end of shaft 301 meshes with a rack bar 3I0 fixed to a slide 3| I. The latter is slidably mounted in a slot of the bolster block 304 and held in place by a cover plate M2. The slide 3 has journaled upon it a roller 3I3 which engages in the groove 314 of a barrel cam M5 on .cam shaft 30. The mechanism just described imparts reciprocating movement to the car 300 at the proper time.

The car 300 has a wire guide 320 at its right end, through which the wires B and S .pass. to a second wire guide 32L Both of these guides converge the wires until at the left end of the guide 32l the wires S and B have been brought close together and to the same level, where they are fed into grooves (Figs. 18 and '19) 322a, 322b,

322a and 323a and 323b, in a guide plate 324.-

It can be seen in' Fig. 18 that the brush wires B are arranged in two layers in each of the grooves 322a, 322b, 3220 and in three tiers in each groove. Each spacer wire S occupies its entire groove 323a, or 323D. At the left end of the plate 324 the grooves are covered by a plate 325. This plate has two' square vertical holes 328 and 329 (Fig. 21). The rear hole 328 contains a'set of clamping plates for the brush wires B (Fig. 18) while the front hole 329 contains clamping blocks for the spacer wires S (Fig. 19). There is a clamping plate 330 for each tier of brush wires B, the plates in each group being separated by thin spacers 33l and the groups being separated by wide spacer blocks 332. The clamping plates 330 have the form shown in Fig. 18a, a hole 333 being cut out near the top of the plate, to leave a slightly springy bail 334 adapted to yield under the pressure of a plunger 335 bearing upon the whole set of clamping plates. The purpose of this construction is to exert uniform clamping pressure on each vertical tier of brush wires, regardles s of slight irregularities in these wires which might cause relative slippage if the entire group of six wires are clamped by a solid plate. As shown in Fig. 19, there is a single clamping plate 331 for each spacer wires, the two plates 331 being positioned in the. hole 329 by three spacer blocks 338. A'plunger 338 bears upon the clamping plates 331. The two plungers 335 and 339 are slidably mounted in' two sockets at the end of a lever 340 pivoted at 34! to a bracket. 342 secured to the car 300. The plungers 335 and 339 are pressed downward by springs 343 and 344. A roller 345 is journaled in two ears 348 standing up from the lever 340. Upon this roller rests one end of a lever 341 pivoted at 348 to 356a (Fig. 20) of thecorrect size to pass the'en-,

tire bundle of brush wires and spacer wires in contiguous relation. This slot is positioned in registration with the end of the bore of ferrule which stands at the wire feeding station.

As can be seen in Fig. 21, the needle block is spaced from the periphery of the index ring by a narrow gap, this gap being just wide enough for the passage of a thin cutting wheel. The upper needle block 351 has a vertical bore aligned with a similar bore in the bridge plate 356. In these bores is slidably guided a plunger 366 which rests at its lower end upon the bundle of wires. At the top of the plunger 366 there is an enlargement of the bore in the bridge plate, which contains a spring 361 interposed between the head of the plunger 366 and the foot of a second plunger 362 slidably guided in a continuation of the bore in the bridge block. The plunger 362 projects from the top, of the bridge plate into contact with the left end of lever 341. The right end of the lever 341 is formed with a pin 363 embraced by two jaws 364, 365 of a lever 3 66 fixed upon a shaft 361. The jaw 364 is pivoted by a pin 368 to a plate 369 fixed by.a screw 316 to the jaw 365. A bracket 311 fixed by a screw 312 to the jaw 364 is bent over at its upper end to enclose a spring 313, which bears against the jaw 365'. A set screw 314 screwed into the top of the bracket 311 has a shoulder bearing against the top of the spring 313 and serves to adjust the compression of the spring. The shaft. 361 ofthe lever 366 is journaled in a bearing 315 and has fixed to 'its opposite end an arm 316 carrying a roller 311 which engages in a camgroove 318 of a face cam 319 (Fig. 2) on the end of the barrel cam 315. The cam 319 rocks the lever 366 counterclockwise to press the plungers 335 and 339 against the clamp plates 336 and 331, with a yielding pressure determined by the springs 343 and 344; Clockwise movement of the lever 366 by cam 319 rocks the lever 341 in the opposite direction, to release the clamp plates 336 and 331 and to press the clamp plunger 366 against the bundle of wires in the needle block 356, with a yielding pressure determined by the springs 361 and 313. The pressure is applied to the clamp plates 336 and 331 before the car 366 starts its movement to the left to feed the wires through the needle block into the ferrule. The clamp plunger 366 is pressed down before the car 366 begins its return movement, in order to hold the wires while the wire guides of the car slip over them during the retrograde movement.

It has been mentioned that the feed,of the brush wires is greater than the feed of the spacer wires, because the former extend considerably further beyond the inner end of the ferrule than the latter. This result is accomplished by a cam fork 386, fixed to the bridge plate 356 and having beveled cam ends 381 adapted to engage the two ends of a long pin 382 extending out from the top of the plunger 339. This engagement occurs when the spacer wires have been fed to the inner end of the ferrule. The plunger 339 is lifted from the clamp plates 331 and further movement of the car 366 to the left is without effect upon the spacer wires.

Kink detector.-Means are provided to detect kinks and irregularities of the wires as they pass from the car 366 to the needle block 356. A slotted bar 396 (Fig. 21) is slidably mounted by screws 391 upon the top of the inner plate 299.-

The left end 392 of the bar 396 is bent at right angles and given a 90 twist, to bring it to a vertical position across the path of the wires. The end 392 has a slot 393 through which the bunch of wiresis threaded, the vertical width of the slot being slightly greater than the vertical dimension of the bunch of wires. The right end of the bar 396 is bent and forked at 394, to embrace a pin 395 located near the mid-point of a lever 396. The lever is pivoted at 391 to a part of the bolster block 364 and forked at its other end to engage a pin 393 on car 366. Thus the bar 396 is given a stroke about half that of the car. The bar 396 and lever 396 are insulated from the body of the machine by means not shown and connected by a wire also not shown in a circuit which will be described later.

.Two guide'bars' 466 and 461 are slidably held in a groove 462 (Fig. 16) of the bolster block 364 and their rectangularly'bent ends 463 and 464 extend through a slot 465 in the bolster block, across the path of the wires. The ends 463 and 464 are slotted similarly to the end 392 of the contact bar, but with smaller vertical clearance from the bunch of wires, so that contact with the wires is maintained and they are accurately guided. The right ends of the guide bars are bent out at 466 and 461 to engage different coils of a spring 468 housed in the groove 462. One end of the spring 468 is anchored to the bolster block 364, while the other end .moks into a bracket 469 fastened to the car 366. The guide bars 466 and 461 and the contact bar 396 are given proportional movements as the car travels to the left, which bring the ends 392, 463 and 464 closer together and nearer to the needle block. The movements are proportioned so that at all times the guide end 463 is about equidistant from the needle block and the contact end 392, while the guide end 464 is about equidistant from the end of the car and the contact end 392. The contact end never touches either of the guide ends. Thus the guide ends support the bunch of wires at all times so that they do not buckle against the contact end and only when there is a kink or bend of one or more of the wires does the bunch touch the side of the groove 393, to complete a circuit which stops I the machine and gives a signal, as will be described presently.

Wire cut-ofi.As soon as the wire feed is complete the cutting wheel 23, (Fig. 2) executes a stroke which carries it through the bundle of wires at the gap between the needle block 356 and the index ring. The cutting wheels 23 is mounted by its arbor 416 in a rocking frame comprising a short arm 411 and a long arm 412. These arms are mounted by a shaft 413 on bearing posts 414 and 415 on the turret cover 18. The long arm 412 extends to the rear beyond the cam shaft 36 where it carries a weight 416 normally holding the frame in position to support the cutting wheel 23 above the bunch of wires. A pin 411 extends through the arm 412 into contact with a cam 418 (Fig. 6) of cam shaft 36. At the proper time the cam rocks the frame and moves the cutting wheel through the bunch of wires. The arbor of the cutting wheel is driven through belts 419 .trained over pulleys 426 on the wheel arbor and pulleys 421 on the shaft 413. Between the pulleys 421 is a pulley 422 over which is trained a belt 423 leading to the pulley 424 of motor 31.

There may be provided means, not shown in thedrawings, for slightly crimping the ferrule against the bunch of wires at the wire threading station.

Brush ejecting stati0n.The ferrule with its complement of wires travels with the index ring, to the ejecting station 24 (Figs. 2 and 6). The ejecting station is directly opposite the roaching station and the ejecting means are operated by'the same slide 241 (Fig. 9) which operates the broach. At the radial plane of each ferrule receptacle of the index ring 9 there are two ejector rods 439 slidably mounted in vertical bores of the index ring. At the brush ejecting station, the ejector rods are positioned over two plunger-s 43i slidably guided in vertical bores of the bed 16. The plungers 43l are pressed downward by springs 432 interposed between their heads 433 and the upper end of enlarged portions 434 of the vertical bores of the bed. The heads 433 rest upon a cam block 435 guided in the slot 242 of the bed 16. The cam block 435 has a longitudinal bore through which passes a headed rod 435 fixed to the end of the slide 24L The cam block 435 does not follow the entire movement of the slide 24! but, being shorter than the distance between the head of the rod 436 and the end of the slide 24L is moved a short distance to the left as the slide 24i nears the left end of its movement, then a short distance to the right as the slide approaches the right end of its movement. The movement to the left of the cam block 435 thrusts the plungers 43i and the ejector rods 439 upward, raising the ferrule of the brush which is in the ejecting position against a knurled wheel 44!). The wheel 449 is constantly rotated in clockwise direction, as seen in Fig, 9, by driving mechanism to be described presently, and thus frictionally drives the brush to the left.

Sizing and straightening unit Upon. being ejected from the index ring. the

brush enters a sizing and straightening unit 25,

shown particularly in Figs. 2, 6, and 25-28. The mechanism of this unit is driven by the motor 33 through a belt I trained over a pulley 442 pinned to the drive shaft 443. This drive shaft has five worm sections 444 spaced along it, with which mesh worm wheels 445 fixed to hubs 445 straightening wheels 459. Positioned above each lower straightening wheel 45!! is an upper straightening wheel 452, the latter being fixed to shafts 453 journaled in rocking supports 454, pivotally mounted in the bolster block by pins 45L The rear ends of shafts 453 have fixed to them gears 455 meshing with gears 456 of the same size fixed to the hubs 446 of worm wheels 445. Between the vertical pairs of straightening wheels 450, 452 are pairs of rollers 451 journaled on stationary shafts 458. The relative positions of the straightening wheels 450, 452 and the pairs of rollers 451 is determined so that the brushes, on their passage through the series, are bent rcversely several times, which straightens their ferrules.

On the shaft 441 at the left end of the ser s is fixed a lower sizing roller 459 and above this is an upper sizing roller 469. The latter is fixed to a shaft 46! journals-d in a bearing 462 pivoted to the bolster block by a pin 463. The bearing 462 has an arm 464 extending to the right and forked at its end to embrace a bolt 465 secured to the bolster block. A spring 466 is interposed between the am 464 and a nut 461 on the bolt 465. The spring normally holds the arm 464 against a stop 468. By turning the nut 461the pressure exerted by the sizing rollers 459 and 460 upon the ferrules passing between them-can be adjusted so as to finish the ferrules to the required size. The shaft 46l of the upper'sizing roll has fixed to its rear end a gear 469 meshing with a .gear 419 on the hub 446 of the worm wheel 44! at the left end of the series. At opposite sides of the sizing wheels 45i, 466 are located two lateral sizing wheels 4H and 412. These are journaled upon short vertical shafts 413.and turn idly as the ferrules are driven between them by the vertical sizing rolls. In front of the sizing rolls is a. flanged guide roll 498', which supports and a gear 418 journaled upon a shaft 416. The gear 418 meshes with an idler gear 419 driven by the gear 469. The knurled wheel 44!] is fixed to a shaft 480 journaled in a bearing block 46i rockably supported upon shaft 416. The shaft 489 is driven by a gear 482 fixed to it, which meshes with an idler gear 483 drivenby the gear 418. At the right end of the series of straightening wheels 459, 452 there is a stripper 494 which deflects the finished brushes into the chute 26.

If the ferrule, upon being ejected by the knurled wheel 440, should fail to pass over the guide roll 413 and should tilt up, the rear end of the brush would strike a contact 485 (Fig. 6)' mounted, with interposed insulation, upon the turret cover 16. The contact 485 is connected in a circuit to stop the machine and give a signal, as will be described later. If the brush should fail to be ejected, the next step of the index ring would bring the brush wires against a contact 485 on an arm 481 fixed to the turret cover 18, with interposed. insulatioh. The contact 486 is connected in a circuit similar to the one containing contact 485.

A contact finger 488 is mounted upon a post 489 on the bed 16, with. interposed insulation. The contact finger 488 is positioned over the top surface of the index ring 9 with small clearance. so that the presence of any conductive dirt or metal particles will short circuit the contact finger to the index ring, thus completing a circuit for stopping the machine and giving a signal: as will be described with reference to the wiring diagram.

Means are providedto insure the return of the ejector rods 430 (Fig. 9) to their lower position. As shown in Figs. 6 and 10, an arm 499 is rockably supported upon a bearing bracket 491 secured to the turret cover 18. At its left end this arm carries two buttons 492 in suitable sockets which do not appear in the drawings. These buttons are pressed downward by springs which also do not appear and press against the tops of plungers 493 slidably mounted in vertical bores in-the turret cover 18. The plungers 493 are held .up bysprings 494 so that their lower ends are normally flush with the bottom of-thecover 18. The plungers 493are positioned directly over the ejector rods 436 in the index position of the index ring and yieldingly-press these rods down as the arm 499 is rocked counterclockwise. The rock ing movement is imparted to the arm by a plunger 495 slidably guided in a bore of the bearing bracket 49L The upper end of the plunger- 495 bears against a leaf spring 496 secured to'the arm 490, while its lower end rests upon the broach slide 220 (Fig. 9). A headed pin 491 socketed in the broach slide moves under the plunger 495 as the slide 220 moves to the right, thus rocking the arm 490.

Vacuum cleaning means are provided as shown in Fig. 2 to keep th index ring clean and remove grindings and cutting chips. The cutting wheel 23 is enclosed by a hood 383 connected by a suction pipe 384 with a suction fan, not shown. A pipe 385 taps into th hood 383 to carry the suction to a nozzle 38-6 positioned over the brush wires, in an aperture 389 in the cover plate 18. 'A pipe 381 carries the suction to a manifold 388 which applies suction to the receptacles of the index ring, before they reach the tube feeding station, and also takes the chips from the tube saw.

Wiring diagram and operation Referring now to the wiring diagram, Fig.- 31,

the main driving motor 500 is connected by wires 50l and 502 and a switch 503 to the line wires 504 and 505 of a source of alternating .current.

wires 5l3, 510, motors 3|, 32, 33, 34, wires -5ll,

5l2, switch 503 to line wire 505. Signal fights 45 go on as each auxiliary motor is turned on, being connected in parallel to their respective motors by wires 53l 532.

The machine is started by engaging the clutch 506, which sets the cam shaft 30 in rotation. The clutch is engaged by energizing the coils of an electromagnet 5l5 acting upon an armature 516 secured to the clutch lever 499. The electromagnet coils are energized by closing a switch 5| and depressing the starting button 43, through the following circuit: from the positive side 5| 1 of a source of direct current, through switch 5, wire 5I9, switches 520, 52L 522, 523,

interconnected by wires 524, wire 525, push button switch 43, 44, wire 526, electromagnet coils 5l5, wire 521, the other side of switch 5! 8, to the negative side 528 of the source of current. If it is desired tojog the cam shaft ahead, the jo switch 41, connected in parallel to the push button switch 43 by wires 5 and 534, may be ope'rated. A lamp 46 connected in parallel to the electromagnet coils 5I5 by wires 529 and 530 is illuminated Whenever the clutch is engaged.

It has been previously mentioned that the machine is stopped and a signal given whenever any abnormal condition occurs, such as exhaustion of the tube supply, a kink in the wires, etc. The machine is stopped by breaking the circuit of the clutch magnet 5l5 at one of the switches 520-523. These switches are normally closed and are adapted to be opened by electromagnets 520a, 52la, 522a, 523a. The electromagnets are energized by a transformer 535, the primary coil 536 of which is connected across the alternating current supply lines 508, 5l2 by wires 531 and 533. The circuit of the electromagnet 520a controlling the switch 520 is closed by either one of the contact devices 54 or 392, for detecting irregularities of the :brush wires. the circuits being as follows: from the secondary winding 540, of the transformer 535, wires 54!, 542, 543, electromagnet 520a, wires 544, 545, thence either through wire 546, contact 392 and the brush wire to ground contact 392a; or through wire 541, contact 54 and the brush wire to ground contact 54b;

thence through the machine frame 81 to wire 549 and back to the secondary winding 540. The

energization of electromagnet 520a, through the closure of one of the circuits just described, opens the switch 520 and deenergizes the clutch magnet 5l5, the clutch being disengaged by its spring 501. Simultaneously with the excitation of electroinagnet 520a to stop the machine, signal light 48 is illuminated to indicate the location of the trouble, this light being connected in parallel to similar to the circuits for the electromagnet 520a and signal light 48 except that they pass through common wire 552 and either wire 553 or 554, through contact 486 or 485, through th brush to the ground contact 486a or 485a.

The electromagnet 522a is excited to open switch 522, and the signal lamp 50 is illuminated. whenever dirt is detected on the index ring by contact finger 488, or an empty ferrule receptacle is detected by switch 205. The circuits are again similar to those previously described, except that they pass through common wire 555, and either wire 556 or 551, and through contact 488 or switch 205, to ground contact 488a or 205a.

The electromagnet 523ais excited to open switch 523, and the signal lamp 5| is illuminated,

7 whenever the tube supply is exhausted, as detected by bail switch I36, or whenever the feed of the tube to the index ring is irregular, as detected by feeler switch arm 202. The circuits from the transformer 535 through the electromagnet 323a and signal lamp 35l are similar to those previously described, while their contact with the ground is made through either of the following circuits: (1) common wire 560, wire 56l, contact points 562 and 563, normally open but closed by a cam 564 on cam shaft 30 during a portion of each rotation of the cam shaft, wire 565, contact bail I36, now dropped to the grounded shoulder I 38 of the tube feed car. (2) From common wire 560 through wire 566, across contact points 561 and 568, closed for a portion of each rotation of the cam shaft by a cam 569, wire 510, contact 51! operated by button 201 and feeler lever 202, to either one of grounded contacts 512 or 513, depending upon whether the tube is fed not far enough or too far, thence bywire. 514 to -the frame 81. The cam 569 closes the contacts 561, 568 just before the index ring feed dog 82 starts its operative stroke. If at this time the contact 513 is in engagement with either contact 512, because the tube has not been fed far enough, or with contact 513 because the tube has been fed too far, the circuit will be completed and the clutch magnet 5| 5 will bedeenergized to disengage the clutch before the index ring is started from the index position. The switch 200 is coordinated with switch 561, 568 operated by a cam on the cam shaft, in order to stop the index ring in the index position, where the trouble can be investigated before any damage is done by an improperly positioned ferrule, and for the further reason that the switch 200 is only held 

